A method for manufacturing a ring (i.e. class, championship, or affiliation) begins by receiving order data specifying a series of personalization elements, such as the addition of text and icon designs. A geometric model for each personalization item is constructed. To assemble text panels, the operating system provides font geometry for a desired TrueType font. Then a set of splines are created from the font geometry and are then tessellated to generate polyline sets of data, which are then spaced and mapped between two boundary curves. The personalization elements are then projected onto one of the model's 3D surfaces. A set of machining instructions for a milling machine is generated by obtaining a set of machining pattern strategies, generating a set of curves, projecting the toolpath onto the surface of the ring to calculate the 3D toolpath, and rotating it to a desired angle.
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1. A method for manufacturing a customized item, comprising:
receiving order data, where the order data specifies a first personalization element;
constructing a geometric model for the customized item, wherein constructing a geometric model comprises at least one of:
retrieving one or more stock or icon panels from a repository; and
assembling one or more text panels for a personalization text in a specified font;
scaling the first personalization element to proper size;
projecting the first personalization element onto a three dimensional surface of the geometric model; and
converting the geometric model into a set of machinery instructions for a milling machine compensating for cutter geometry.
12. A system for manufacturing a customized item, comprising:
an order module that receives order data, where the order data specifies a first personalization element;
a construction module that constructs a geometric model for the customized item, wherein the construction module comprises at least one of:
a panel retrieval module that retrieves one or more stock or icon panels from a repository; and
a panel assembly module that assembles one or more text panels for a personalization text in a specified font;
a scaling module that scales the first personalization element to proper size;
a projection module that projects the first personalization element onto a three dimensional surface of the geometric model; and
a conversion module that converts the geometric model into a set of machining instructions for a milling machine compensating for cutter geometry.
23. A computer program embodied on a computer readable medium, when executed by a computer configures the computer to manufacture a customized item, the computer program comprising:
a code segment for receiving order data, where the order data specifies a first personalization element;
a code segment for constructing a geometric model for the customized item, wherein the code segment for constructing a geometric model comprises at least one of:
a code segment for retrieving one or more stock or icon panels from a repository; and
a code segment for assembling one or more text panels for a personalization text in a specified font;
a code segment for scaling the first personalization element onto a three dimensional surface of the geometric model; and
a code segment for converting the geometric model into a set of machining instructions for a milling machine compensating for cutter geometry.
34. A method for manufacturing a customized item, comprising:
receiving order data, where the order data specifies a first personalization element;
constructing a geometric model for the customized item, wherein constructing a geometric model comprises at least one of:
retrieving one or more stock or icon panels from a repository; and
assembling one or more text panels for a personalization text in a specified font, wherein the step of assembling one or more text panels comprises:
retrieving the personalization text and a design number from the order data;
receiving font information for the specified font;
requesting and receiving font geometry from an operating system;
constructing a plurality of splines from the font geometry;
mapping the personalization text onto a two dimensional frame using the font geometry;
tessellating the plurality of splines for generating a polyline data representation, wherein the polyline data representation comprises a plurality of polyline sets, wherein each of the polyline sets describes a character of the personalization text;
processing each of the polyline sets based on kerning data for properly spacing each character of the personalization text; and
mapping the polyline data representation between two boundary curves;
scaling the first personalization element to proper size;
projecting the first personalization element onto a three dimensional surface of the geometric model; and
converting the geometric model into a set of machinery instructions for a milling machine compensating for cutter geometry.
2. The method for manufacturing a customized item from
3. The method for manufacturing a customized item from
4. The method for manufacturing a customized item from
retrieving the personalization text and a design number from the order data;
receiving font information for the specified font;
requesting and receiving font geometry from an operating system;
constructing a plurality of splines from the font geometry;
mapping the personalization text onto a two dimensional frame using the font geometry;
tessellating the plurality of splines for generating a polyline data representation, wherein the polyline data representation comprises a plurality of polyline sets, wherein each of the polyline sets describes a character of the personalization text;
processing each of the polyline sets based on kerning data for properly spacing each character of the personalization text; and
mapping the polyline data representation between two boundary curves.
5. The method for manufacturing a customized item from
6. The method for manufacturing a customized item from
a font name parameter, a character spacing parameter, a character thickness parameter, a character type parameter, an upper boundary curve parameter, and a lower boundary curve parameter.
7. The method for manufacturing a customized item from
obtaining a plurality of machining patterns and associated cutting tools;
generating a first set of curves that define a first two dimensional toolpath based on cutter geometry for a first machining pattern from the plurality of machining patterns;
projecting the first two dimensional toolpath onto a surface of the customized item to generate a first three dimensional toolpath;
repeating steps of generating, projecting and rotating for a second machining pattern from the plurality of machining patterns to obtain a second resulting toolpath;
appending the second resulting toolpath to the first resulting toolpath to generate a master toolpath; and
converting coordinates from the master toolpath to a generic format file.
8. The method for manufacturing a customized item from
a raster pattern, wherein Voronoi diagram techniques are used to generate two dimensional offsets defined by text geometry, cutting tool shape, and cutting depth;
a profile pattern, wherein Voronoi diagram techniques are used to generate two dimensional offsets defined by text geometry, cutting tool shape, and cutting depth;
a skeleton pattern, wherein Voronoi diagram techniques are used to generate medial axis transforms defined by text geometry, cutting tool shape, and cutting depth;
a two dimensional curve machining with surface projection pattern; and
a three dimensional curve machining pattern.
9. The method for manufacturing a customized item from
10. The method for manufacturing a customized item from
11. The method for manufacturing a customized item from
13. The system for manufacturing a customized item from
14. The system for manufacturing a customized item from
15. The system for manufacturing a customized item from
a text retrieval module that retrieves the personalization text and a design number from the order data;
a font information module that received font information for the specified font;
a font geometry module that requests and receives font geometry from a an operating system;
a spline construction module that constructs a plurality of splines from the font geometry;
a frame mapping module that maps the personalization text onto a two dimensional frame using the font geometry;
a tessellating module that tessellates the plurality of splines for generating a polyline data representation, wherein the polyline data representation comprises a plurality of polyline sets, wherein each of the polyline sets describes a character of the personalization text;
a polyline processing module that processes each of the polyline sets based on kerning data for properly spacing each character of the personalization text; and
a polyline mapping module that maps the polyline data representation between two boundary curves.
16. The system for manufacturing a customized item from
17. The system for manufacturing a customized item from
a font name parameter, a character spacing parameter, a character thickness parameter, a character type parameter, an upper boundary curve parameter, and a lower boundary curve parameter.
18. The system for manufacturing a customized item from
a pattern retrieval module that obtains a plurality of machining patterns and associated cutting tools;
a curve generation module that generates a first set of curves that define a first two dimensional toolpath based on cutter geometry for a first machining pattern from the plurality of machining patterns;
a toolpath projection module that projects the first two dimensional toolpath onto a surface of the customized item to generate a first three dimensional toolpath;
a toolpath rotation module that rotates the first three dimensional toolpath by a first angle associated with the surface of the customized item to obtain a first resulting toolpath;
a second toolpath creation module that leverages the curve generation module, the toolpath projection module, and the toolpath rotation module for a second machining pattern from the plurality of machining patterns to obtain a second resulting toolpath;
an master toolpath creation module that appends the second resulting toolpath to the first resulting toolpath to generate a master toolpath; and
a generic toolpath creation module that converts coordinates from the master toolpath to a generic format file.
19. The system for manufacturing a customized item from
a raster pattern, wherein Voronoi diagram techniques are used to generate two dimensional offsets defined by text geometry, cutting tool shape, and cutting depth;
a profile pattern, wherein Voronoi diagram techniques are used to generated two dimensional offsets defined by text geometry, cutting tool shape, and cutting depth;
a skeleton pattern, wherein Voronoi diagram techniques are used to generate medial axis transforms defined by text geometry, cutting tool shape, and cutting depth;
a two dimensional curve machining with surface projection pattern; and
a three dimensional curve machining pattern.
20. The system for manufacturing a customized item from
21. The system fro manufacturing a customized item from
22. The system for manufacturing a customized item from
24. The computer program for manufacturing a customized item from
25. The computer program for manufacturing a customized item from
26. The computer program for manufacturing a customized item from
a code segment for retrieving the personalization text and a design number from the order data;
a code segment for receiving font information for the specified font;
a code segment for requesting and receiving font geometry from an operating system;
a code segment for mapping the personalization text onto a two dimensional frame using the font geometry;
a code segment for tessellating the plurality of splines for generating a polyline data representation, wherein the polyline data representation comprises a plurality of polyline sets, wherein each of the polyline sets based on kerning data for properly spacing each character of personalization text; and
a code segment for mapping the polyline text representation between two boundary curves.
27. The computer program for manufacturing a customized item from
28. The computer program for manufacturing a customized item from
a font name parameter, a character spacing parameter, a character thickness parameter, a character type parameter, an upper boundary curve parameter, and lower boundary curve parameter.
29. The computer program for manufacturing a customized item from
a code segment for obtaining a plurality of machining patterns and associated cutting tools;
a code segment for generating a first set of curves that define a first two dimensional toolpath based on cutter geometry for a first machining pattern from the plurality of machining patterns;
a code segment for projecting the first two dimensional toolpath onto a surface of the customized item to generate a first three dimensional toolpath;
a code segment for rotating the first three dimensional toolpath by a first angle associated with the surface of the customized item to obtain a first resulting toolpath;
a code segment for repeating the use of the code segment for generating, the code segment for projecting and the code segment for rotating a process a second machining pattern from the plurality of machining patterns, to obtain a second resulting toolpath;
a code segment for converting coordinates from the master toolpath to a generic format file.
30. The computer program for manufacturing a customized item from
a raster pattern, wherein Voronoi diagram techniques are used to generate two dimensional offsets defined by text geometry, cutting tool shape, and cutting depth;
a profile pattern, wherein Voronoi diagram techniques are used to generate two dimensional offsets defined by text geometry, cutting tool shape, and cutting depth;
a skeleton pattern, wherein Voronoi diagram techniques are used to generate medial axis transforms defined by text geometry, cutting tool shape, and cutting depth;
a light skeleton pattern, wherein Voronoi diagram techniques are used to generate medial axis transforms defined by text geometry, cutting tool shape, and cutting depth;
a two dimensional curve machining with surface projection pattern; and
a three dimensional curve machining pattern.
31. The computer program for manufacturing a customized item from
32. The computer program for manufacturing a customized item from
33. The computer program for manufacturing a customized item from
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The process of the present invention relates to the manufacture of personalized items such as jewelry. More particularly, the process of the present invention relates to an automated system that receives custom orders for personalized rings (i.e., class, championship, and affiliation) and generates the machining instructions that enable a milling machine to create the personalized ring from a wax blank.
Class rings have been a popular keepsake among students for generations. Originally, they were relatively uniform and provided students little opportunity to express themselves. Over time, automated manufacturing processes made it possible to provide students customizing choices. Modern students are driving the class ring market toward a level of customization that has been previously economically impractical using present manufacturing methods.
Present manufacturing methods include the use of computer aided design/computer-aided manufacturing (CAD/CAM). CAD/CAM has facilitated producing customized rings in large quantities. The present level of customization provides personalized features such as: student's name, school name, graduation year, icons, academic degrees, and the like.
Traditionally, the use of CAD/CAM in the jewelry industry has been primarily focused on the manufacture of custom molds and engraving or otherwise machining the jewelry directly. These two approaches have limitations. Machining molds using CAD/CAM is too expensive for single-use custom applications. Engraving jewelry is also expensive due to the precious metal lost to scrap, manufacturing errors and ordering errors.
CAD/CAM technology is also difficult to automate for the purpose of making personalized products. In one legacy system, a CAD/CAM operator manually manipulates a geometric model of a ring by grabbing a surface on the blank geometric model, defining the boundary splines, projecting the text or graphic onto the surface and then instructing the CAD/CAM software to generate machining instructions for the geometric model that has been created. The machining instructions result in a desired toolpath for a computer numerically controlled (“CNC”) milling machine. Using human operators to repeat these steps manually in order to generate the machining instructions for thousands of individual, personalized rings is cost prohibitive.
The present invention provides a cost effective solution to the problems discussed above. One aspect of the present invention is directed toward reducing the amount of precious metal lost to scrap. As opposed to personalizing jewelry by machining personalized features directly into the precious metal, work is performed, using CAD/CAM, onto a wax blank. The finished wax replica is then used to produce a mold, into which precious metal is poured to produce the desired product.
Using wax in this manner provides numerous advantages over direct machining. First, wax is much softer than metal. Thus, the need for expensive cutting tools is minimized and the tool life of the cutting tools that are needed is greatly extended. Additionally, smaller, more delicate tools can be used to achieve more intricate artwork than possible using beefier, metal-cutting tools.
The increased level of detail allowed by working with wax facilitates an increased offering of choices to jewelry customers. For example, previous personalization options included individualized alphanumeric features such as names or class years. In previous systems, to support personalized rings having students' names, an insert was machined for each name. Thus, when a student named “Mike” ordered a ring with his name on it, the Mike-insert was retrieved and used to cast the ring. Whenever an order included a new name, a new insert would be created. In recent years, more and more parents have adopted unique names for their children. This has resulted in the need for the creation and storage of many more name inserts. In the present invention, by using wax, more precisely defined tapered cutting tools and TrueType typography technology (available from AGFA-Monotype), students can choose to have their name (whether the common or uncommon) engraved in any of a multitude of digital fonts. The present invention also provides a higher level of definition, which allows more alphanumeric characters to be engraved on a ring than was previously available.
Another advantage of wax is that it is very inexpensive. Using wax not only eliminates much of the scrap metal produced by direct machining of jewelry, if ordering errors or manufacturing errors arise in the wax product, no precious metal is lost due to the error.
Another aspect of the present invention is an automated toolpath-generating program for use in milling the customized ring's wax model. The computer system of the present invention creates a geometric model, from which machining instructions are automatically generated and temporarily stored for each text or icon panel for the ring. These machining instructions support both tapered and cylindrical cutter tools as defined by the APT-7 cutting tool geometry model. Once created, the machining instructions are fed directly to a CNC milling machine that creates the wax model. Thus, the CAD/CAM operator is eliminated from the process, thereby greatly increasing production volume and decreasing production costs.
Referring to
A workstation 215 is managed by a production operator. From this workstation 215, a computer software application can retrieve data for one of the pending orders. The order for a class ring includes all of the personalization to be applied to the ring. For example, the order specifies which type of ring to use, where to engrave the student's name, what font to use, where to place school and year information, where to apply icons representative of the student's interests, etc. The software application applies all of the personalization elements to a 3D virtual model of the ring. Then it translates the model into a series of instructions describing a path that a milling machine's cutting tool follows while machining a ring. This set of instructions are commonly known as the “toolpath”. The toolpath is downloaded to a milling machine 225 and a wax blank of the ring is engraved to the specifications ordered by the student. The resulting wax model is then grouped with other wax models and the set of rings are cast and finished 230, resulting in the customized ring 235.
A toolpath viewer 325 can be used to provide a preview visualization to the production operator of what will result when the toolpath is applied to the wax blank. In one embodiment, WNCPlot3D viewer software (sold by Intercim) is used as the toolpath viewer 325. The viewer 325 is used mostly in troubleshooting and setup situations.
Once the personalization client 310 and personalization server 315 assemble the generic toolpath (preferably an “ACL” (i.e., Intercim's “ASCII Cutter Location”) format file based on the APT (Automatically Programmed Tool) standard), a post-processor 320 (such as Intercim's GPOST post-processor) can be used to translate it to the mill-specific toolpath, which is then downloaded to the milling machine 225.
While the architecture shown in
Based on the font geometry, a set of splines are created 620. To construct the splines from the native font geometry, data from the TrueType font information returned by the operating system is used to construct curves in spline format. The text is then mapped between upper and lower boundary curves which define the panel shape in 2 dimensions. This is accomplished with the font geometry information. The first step is to tessellate all of the splines to generate a polyline set for each character of the text 625. The text characters are mapped into a 2D rectangular domain using the kerning information provided with the TrueType font 630. Because kerned type is often more pleasant looking than fixed-spaced type, each of the polyline sets are spaced based on kerning data supplied with the font geometry. The spacing is adjusted to meet the minimum spacing requirements associated with the given panel 635. Once this modification of the text is finished, the polyline sets are mapped between the boundary curves 640 so that the characters or icon curves follow the shape of the two boundaries. To do this, a ruled surface is defined between the two curves. Such a process is discussed in “The NURBS Book” by Les Piegl and Wayne Tiller (pages 337–339) and is illustrated in
The coordinates of the text or icon curves are scaled to fit into the domain of the newly created ruled surface, and their scaled coordinate values are interpolated using the definition of the ruled surface.
In some embodiments, configuration parameters are retrieved from a repository. The configuration parameters vary for each ring design. Thus, for each ring, the repository may store such data as the font name, character spacing, character thickness, character type (such as raised, incised, etc.), boundary curves, cutter type, and machining pattern.
With respect to the light skeleton pattern, it may be generated by constructing the Voronoi diagram of the set of input curves and extracting a subset of the Voronoi diagram that is sometimes referred to as a symmetric axis transform. A z-depth is assigned to each point of the subset of the Voronoi diagram, based on the distance from the point to the two curves associated to the point and the shape of the cutting tool. By combining this light skeleton pattern with the profile pattern, the result is the skeleton pattern. For the 2D curve pattern, the invention projects the curves vertically onto a surface.
In one embodiment, the geometry being machined is approximated by 2½-dimensional geometry. That is, it is assumed that the objects are two dimensional with a nearly constant z-height. This assumption is valid for many of the ring manufacturing designs. Thus (referring back to
Referring now to
As shown in
As discussed above, the light skeleton and full skeleton patterns are related. Referring to
Now referring back to
In the same fashion, all of the remaining personalization panels are processed 740, and the resulting toolpath is concatenated for each iteration 735. In one embodiment of the invention, up to ten personalization items can be handled, meaning that up to ten separate toolpaths are generated and concatenated into a single, master toolpath file. After all panels are processed, the toolpath is converted to the generic ACL format 430. In one embodiment, this conversion is accomplished by a post-processor, such as the Intercim GPOST software product 440.
In
The foregoing description addresses embodiments encompassing the principles of the present invention. The embodiments may be changed, modified and/or implemented using various types of arrangements. Those skilled in the art will readily recognize various modifications and changes that may be made to the invention without strictly following the exemplary embodiments and applications illustrated and described herein, and without departing from the scope of the invention, which is set forth in the following claims.
Carbonera, Carlos D., Malinin, Yuriy, Saarela, Timothy D., Frisch, Michael J.
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